Alright. It's been two weeks and my 2000 Sportsman 500 still has no spark. After replacing the whole ignition system (ignition coil, stator with pickup coil, plug, wire, CDI, voltage regulator, solenoid) I still have no spark. I checked the ETC and it's working fine. I even adjusted the cable a bit. Why I am posting is because I just bought this about three weeks ago and it has only ran for the first week. Of course no kind of warranty as it was a private sale. It happened while I was plowing. I just finished a short run at the end of my driveway and it died. Would crank but wouldn't turnover.
I am thinking it has to be either the left handlebar switch housing or the ignition switch. Here's one last key detail. When the ignition switch is off I do not get connectivity between any black and brown (ground) wire. If I turn the ignition on I get connectivity tone between all my ground and black (kill switch) wires. I disconnected the kill switch wires from the CDI as well. Still nothing. I also took off all the plastics and pulled off all the black wire looms and went through as much as possible while putting dielectric grease on every connection possible.
I am desperate honestly as this is becoming a real money pit. Of course this isn't making the wife happy since I planned on bringing in some extra money doing some sub contract plowing with the quad and my two snowblowers.
Any ideas no matter how crazy please post. My two choices right now is take it to a shop for $80 an hour to diagnose or buy a switch housing for $180 from Polaris. Either way I don't think there are any guarantees. I am just at my wits end and really can't afford another costly part. Being electrical parts of course you can't return them.
I also tested all the resistance on the stator, pickup coil, solenoid, etc. Everything is checking out to the specs in the full service manual I have. I was thinking of running another ground but I have solid connectivity on the two grounds as it is.
Thanks for reading.
I am thinking it has to be either the left handlebar switch housing or the ignition switch. Here's one last key detail. When the ignition switch is off I do not get connectivity between any black and brown (ground) wire. If I turn the ignition on I get connectivity tone between all my ground and black (kill switch) wires. I disconnected the kill switch wires from the CDI as well. Still nothing. I also took off all the plastics and pulled off all the black wire looms and went through as much as possible while putting dielectric grease on every connection possible.
I am desperate honestly as this is becoming a real money pit. Of course this isn't making the wife happy since I planned on bringing in some extra money doing some sub contract plowing with the quad and my two snowblowers.
Any ideas no matter how crazy please post. My two choices right now is take it to a shop for $80 an hour to diagnose or buy a switch housing for $180 from Polaris. Either way I don't think there are any guarantees. I am just at my wits end and really can't afford another costly part. Being electrical parts of course you can't return them.
I also tested all the resistance on the stator, pickup coil, solenoid, etc. Everything is checking out to the specs in the full service manual I have. I was thinking of running another ground but I have solid connectivity on the two grounds as it is.
Thanks for reading.